Transfer Case: Testing and Inspection

Borg Warner - Symptoms

Oil leaks
1. Check that nylon ventilation pipes are not blocked or damaged.
2. Check lubrication level and specification in both boxes and recheck leaks.
3. Location area of leak.
A - Transfer box front output flange oil seal.
B - Transfer box rear output flange oil seal.
C - Oil leaking from vent hole between main and transfer boxes. The oil may be leaking from the main or transfer box oil seals. Renew the faulty seal.
D - Oil leaking from engine flywheel housing. The oil may be leaking from the gearbox front seal, torque converter seal or the engine crankshaft rear seal. Renew the faulty seal.

Loss of drive - no abnormal noise from box.
1. Check that the main transmission unit is satisfactory and confirm that loss of drive is in the transfer box.
2. Check by 'feel' the operation of the High/Low transfer gear selection. Suspect failed viscous unit.

Knocking or rattling noise in high and low ratio.
1. Check lubricant specification and level, if low do not top up at this stage.
2. Drain lubricant and check for contamination or metal particles.
Suspect drive chain has stretched.

Abnormal noise in operation.
1. Check lubricant specification and level, if low do not top up at this stage.
2. Drain lubricant and check for contamination or metal particles.
Suspect oil pump failure, mechanical wear or damage.

Transmission wind up
'Transmission wind up' is a build up of tension in the transmission which will only occur if either the differential or viscous unit is partially or completely seized.

Vibration - harshness
1. Check operation of differential and viscous units. Ensure that neither is partially seized.

NOTE: If both are satisfactory, but the vibration - harshness is still present, the alignment of the propeller shafts and balance of the road wheels should be checked.